The aim of the paper is to report a dual-cure powder coatings hybrid system that combine the benefits of free radical polymerization and photo-cationic polymerization and overcome their limitations. The coating is based on solids epoxy polyester and solid urethanized acrylate. The final coatings properties are achived by the combination of free radical and cationic polymerization in the presence of hydroxyl-ketone initiator and photo acid generated initiator. Single source UV-light irradiation was employed to produce either single stage or dual-stage hybrid polymerization. The cure film are more flexible, adhere better to the substance and does not have a pin hole compare to 100% free radical or cationic system. Also, the “dark cure” mechanism provides a mean to cure the film in areas not fully exposed to the light.

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